Office Kaizen
- 1. Office Non-Conformance Kaizen Team 10/17/11 to 10/24/11
- 2. Office Team Charter Problem Statement: Overwhelming non-conformances in the office effecting business and cost of quality.
- 3. Office Team Charter Problem Statement (continued): There is no current method for trending and identifying non-conformances with a plan of action and monitoring the effectiveness of the actions taken. The Story Begins……..
- 4. Team Charter GOALS: 1.Confidential survey taken by the office. 2.Trend current non-conformances. 3.Identify root causes (use C.A.R. as a tool). 4.Create checks and balances to minimize non-conformances. 5.Test all new procedures.
- 5. Office Survey Says…. 1. Everyone feels rushed to do their job. It is a fast paced atmosphere. 2. Training is inconsistent or not done at all. 3. Large amounts of interruptions throughout the day. (ex. phone calls, meetings, questions) 4. Quote forms are not being used or properly completed. 5. 63.6% believe the office is following ISO, 36.4% believe they are not. GOAL 1 on team charter: Confidential survey
- 6. 5S scores by kaizen team New form used. 2.66 and 2.90
- 7. 25 Current Non-Conformances 17 Failure to use Docket Checklist 5 Lack of training 3 Undetermined Our Baseline GOAL 1 on team charter: Trend current non-conformances. GOAL 2 on team charter: Identify root cause
- 8. We don’t have enough time to do it right, but we have time to do it over? Docket Check List Pictured is 17 Non-conformances resulting from not using the docket checklist.
- 9. BEFORE AFTER NEW Checklist and Overlay GOAL 3 on team charter: Create checks and balances to minimize NCs. Visual tools for error-proofing.
- 10. EXAMPLES of PULL Lean principles state to create pull where flow is not possible. See what your department’s day looks like.
- 11. Visual Office BEFORE At a glance, can you see the production levels?
- 12. Visual Office AFTER Pull system to help productivity, communication, and lower errors. Productivity levels evident for areas that need help. Top 2 concerns on survey: Feeling rushed and lack of training.
- 13. Visual Office: HOW IT WORKS .
- 14. Kaizen Team Follow-up: 1) 30 day observation on Pull System with collaboration. 2) Trend root cause on future NCs from the office. Observe mandatory use of Docket Check list and Overlay. 3) Propose weekly analysis of Office NCs by metric owner and Office member with C.A.R. training to increase dialogue with all Office members. Docket Check List, Overlay, Visual Pull GOAL 5 on team charter: Monitor effectiveness of actions taken.
- 15. Summary 1. Kaizen team respected the office’s confidentiality and listened to their concerns. A pull system is in place to evenly distribute the work load and allow time to train. 2. Current NCs were trended and a large amount resulted in not using a current tool to increase quality, the docket checklist. 3. The docket checklist was revised and an overlay was created. 4. The Kaizen team will monitor all the above improvements after a specified time.
Editor's Notes
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